Powering Down

May 12, 2025

The McKee Run Generating Station in Dover, Delaware, represented an earlier era of power generation. Constructed in 1961, the station featured two Westinghouse 16.5 MW units (units 1 and 2) that originally burned coal. By 1972, operations converted to fuel oil and natural gas for power generation. That same year, Unit 3 was added, a 102 MW GE steam turbine with a Riley Stoker boiler capable of burning gas or No. 6 fuel oil. In 2008, all units were converted to burn No. 2 fuel oil and gas.

However, despite upgrades, the plant’s aging infrastructure struggled to meet the increasingly strict environmental regulations and growing demand for cleaner, more efficient energy solutions. Units 1 and 2 were retired in 2017, and in June 2021, the entire plant ceased operations permanently. The closure reflected a broader industry trend to phase out older, less efficient facilities in favor of sustainable energy alternatives.

The Bid

The city of Dover selected NDA member Total Wrecking & Environmental (TWE) through a competitive bid process. The selection process included bid submissions, contractor shortlisting, interviews and public city council review meetings to ensure transparency. TWE stood out due to its proven track record in completing large-scale, complex industrial projects on time, safely and efficiently.

What ultimately set TWE apart was its commitment to safety, sustainability and community protection, values shared by the city of Dover. The city had a strong focus on minimizing the impact of the demolition on surrounding residential neighborhoods, and TWE wholeheartedly aligned with this priority.

The Strategy

The project, launched in January 2024, was initially slated for 10-14 months. However, TWE completed the work ahead of schedule in just nine months, wrapping up by October 2024. At its peak, the operation involved a 46-person crew, split evenly between demolition and asbestos abatement teams.

The demolition required a fleet of heavy equipment, including 100,000-pound excavators equipped with demolition shears, grapples, concrete processors and hydraulic hammers; a 110-foot highreach excavator with a shear attachment; 6-foot torches to assist with precision cuts during demolition; and additional support equipment, including a 950 front loader and a 10,000-pound telehandler.

The demolition strategy prioritized salvaging equipment and materials for recycling and resale. Key highlights included:

• Strategic removal: Salvageable turbine shafts and copper wiring were carefully cut and extracted for resale.
• Precision execution: Structures such as the boiler and two stacks were dismantled with pinpoint accuracy, critical given the plant’s close proximity to residential neighborhoods.

The Process

TWE’s methodical approach ensured both safety and sustainability:

1. Secure the site: The site was secured to ensure safety and compliance.
2. Remove asbestos: Crews began asbestos abatement while copper and salvageable materials were removed in accessible areas.
3. Remove hazardous waste: Universal waste, oil and electronic waste were safely extracted for proper disposal or recycling.
4. Dismantle the turbine: Using 6-foot torches, crews carefully cut through turbine shells to remove the shafts, which were rigged and lowered to ground level.
5. Perform mechanical demolition: Cooling towers, located on the north side of the plant, were mechanically dismantled. The two towers measured 155 feet by 53 feet and 180 feet by 54 feet, constructed with pressure-treated wood (arsenic and chromium), fiberglass, plastic fill and trays mounted on concrete bases. The towers also included asbestos siding, fiberglass, metal piping with asbestos coating and rubber-coated wire hangers.
6. Perform structural demolition: The powerhouse, consisting of boilers, turbines, generators, stacks, transformers, warehousing, tanks, operations rooms, maintenance shops, fuel transfer areas and ancillary equipment, was systematically demolished. As the asbestos abatement team completed areas, mechanical demolition continued until all structures were safely brought to the ground.
7. Complete water line grouting: Abandoned circular water lines were flow-filled.
8. Conduct site restoration: The site was backfilled, leveled and graded for final restoration.

The Challenges

The project presented unique challenges. With residential neighborhoods in close proximity, the team had to ensure extreme precision and minimal disruption. Limited space added complexity, particularly when dismantling large structures like boilers and stacks. These challenges were met with meticulous planning and execution, ensuring safety and efficiency.

A Success

By every measure, the McKee Run project was a triumph. With over 36,000 incident-free work hours, TWE demonstrated its commitment to safety. Completing the project ahead of schedule and without a single resident complaint underscored their respect for the community. As TWE sees it, success is about exceeding expectations — delivering on time, safely and sustainably while maintaining positive relationships with all stakeholders.

TWE’s dedication to sustainability was evident in the recycling of 95% of the site’s materials. Salvaged turbine shafts, copper wiring and other materials were repurposed, leaving only the cooling towers to be classified as construction and demolition waste.

The McKee Run demolition not only cleared the way for future development but also set a benchmark for how large-scale industrial projects can be executed with safety, precision and respect for the environment.